MV-CONNEX, HV-CONNEX, IXOSIL Terminations, IXOSIL Slip-on Joints

CABLE SYSTEMS
Accessories and Systems for Medium and
High-Voltage Cables up to 300 kV.
Welcome to the CABLE SYSTEMS
Centre of Competence.
We offer medium and high voltage engineered solutions for cable accessories for virtually all applications up
to 300 kV. All accessories use a silicone rubber insulating medium because of its outstanding properties. We
offer components and complete systems, installation and advisory services, worldwide.

CONNEX. A Dry, Separable Connector System for Medium and

High-Voltage Networks.
CONNEX products provide a universal system of separable connectors: fully insulated with grounded metal
housings. It is virtually maintenance free, suitable for indoor and outdoor use, and water resistant. CONNEX can
be used even under extreme temperatures, from -25C up to +50C (-10 up to +120F).

MV-CONNEX products for medium voltage system (up to 52 kV) include traditional plug and socket combina-
tions, as well as multiple sockets, busbar connectors, surge arresters and voltage detectors.

HV-CONNEX products for high voltage systems up to 245 kV are factory tested, and surprisingly simple to
install. Working in difficult oil and gas environments during installation of transformers and gas insulated
switchgears is finally a thing of the past.

IXOSIL. Cable Terminations.

The extensive range of terminations will handle almost all applications. The silicone rubber insulating medium
enables IXOSIL products to be ideally suited for outdoor use. Self-supporting oil-filled terminations are availa-
ble with silicone rubber coated or porcelain housings. Special designs for indoor use complete the product range.
IXOSIL. Slip-on Joints.
IXOSIL silicone rubber joints can be used to join all XLPE and EPR insulated cables within the range of 72.5
300 kV. Two designs are available: the compact one piece version, and a three piece version for connecting
cables with different shielding and cross sections. Joints can be used on either aluminum or copper cables.

IXOLINE. Factory-Assembled Cables Ready-to-Use.

IXOLINE finished cable sections come with IXOSIL and/or CONNEX terminations. No special tools are
required for installation. Result: increased efficiency, reduced installation time, lower costs.

Silicone a Key Material in High-Voltage Engineering.

Silicone rubber is the perfect material for cable terminations. Water, dirt, grease and oil resistant, completely
maintenance free, shock resistant and unbreakable; it is far superior to traditional materials such as porcelain.
When used as a stress relief device in sealed applications, silicone performs much better than harder materi-
als such as EPDM because it helps to even out temperature variations and unevenness in the cable surface.
Silicone helps to prevent air gaps, and therefore dangerous partial discharges are avoided. PFISTERER takes
extensive advantage of using advanced LSR (liquid silicone rubber) designs, and special variations are desi-
gned using RTV (room temperature vulcanizing silicone).

Worldwide Installation Services.

The installation of high voltage components requires extensive knowledge and care. We share our know-how
with our customers in training courses based on practical applications. If requested by the customer, we can
perform installations anywhere in the world.
Cable Systems | Medium-Voltage

MV-CONNEX 10 kV 52 kV
The MV-CONNEX range is ideal for use in high load ring main units, circuit breaker
switchgear, high voltage motors, transformers, capacitors, transducers and cable
joint boxes. The connectors on the equipment side are designed to meet EN 50180
(bushings for liquid filled transformers up to 52 kV), EN 50181 (plug-in type bushings
up to 36 kV for equipment other than filled transformers) and DIN 47637 (separable
accessories for power cable for bushing with inside cone). The plug is suitable for
most types of insulated plastic cables. In addition to numerous standard versions,
customer specific variations are also available for most cable types. CONNEX can be
provided in other versions for testing purposes and special applications.

Advantages
n metal-encapsulated n free from arcing
n fully insulated n high short circuit resistance
n touch-proof suitable for underground and
n 
n water resistant IP68 offshore applications (special
n zero-maintenance variants)
n suitable for outdoor use

A Contact system
1 contact ring B C
2 tension cone
3 thrust piece D A
8

B Insulating and field-control part

C Housing
4 bell flange
5 pressure sleeve
6 pressure spring
7 heat-shrink
8 test lead (depends on design)
9 cable screen

D Bushing
10 female contact part
11 insulating bushing 10 11 12 1 2 3 6 5 4 7 9
12 housing

Test standard: DIN VDE 0278 Part 6 CONNEX cable connector system
high-current design II Size
0 1 2 3 3-S

Current rating IN (A) 250 630 800 1250 1250

Max. working voltage Um (kV) 24 36 42 42 52
AC voltage test 50 Hz/1 min (kV) 50 70 95 95 117
Nominal withstand lightning impulse voltage 1.2/50 s (kV) 125 170 200 200 250
Partial discharg 2 x UO (pC) 10 10 10 10 10
DC voltage test 15 min 6 x UO (kV) 72 108 125 125 156
Rated short-time withstand current 0.5 sec (kA) - 50 50 63 63
Rated short-time withstand current 1 sec (kA) 16 31.5 40 50 50
Nominal impulse current (kA) 40 125 125 150 150
MV-CONNEX Multi-Contact Elbow
Bushing 24 kV 52 kV
Multi-contact elbow bushings are used instead of DIN-stan-
dard porcelain versions on the medium-voltage side of power
trans-formers. They distribute the current over two or four
cables, thus accommodating higher power loads using more
manageable cable cross sections.

MV-CONNEX Surge Arrester

6 kV 52 kV
CONNEX surge arresters are used to protect metal enclosed
switchgears which have cable terminations in accordance
with EN 50180/EN 50181. Connected to the switchgear or
the transformer, they are particularly effective in limiting sur-
ges caused by reflected travelling waves and switching over
voltages.

MV-CONNEX Busbar Connectors

24 kV 42 kV
The busbar connectors allow modular designed SF6 insu-
lated switchgear to be easily expanded, as the gas com-
partment does not have to be unsealed and opened during
installation. Busbar connectors are available in the 24 kV to
42 kV range.

CMA-MV-CONNEX Motor Connector

The CMA-MV-CONNEX motor connector allows a quick and
easy connection of high voltage motors as a replacement for
the motor connection box. It is fully metal enclosed, and intrin-
sically safe.

Voltage Detecting Systems

Voltage potential can be detected with the integrated capaci-
tive test point system, which includes both mobile and statio-
nary continuous voltage indicators, as well as phase compara-
tors and testing equipment for the voltage indicators.
Cable Systems | High-Voltage

Cable Systems | High-Voltage

The advantages of the CONNEX system are especially evident for high voltage
applications. Simple on-site installation and factory tested, reliable components
provide a safe and cost effective solution. Plug-in HV-CONNEX systems eliminate
costly oil and gas insulation work during the installation process of transformers
and gas insulated switchgear. CONNEX cable joints are more flexible, a big
advantage when building or converting electrical systems. The wide range of pro-
ducts includes all the connection components needed to test the system and the
attached equipment.

Advantages
n The space required for mounting is approximately half that of conventional
systems.
n Flexibility is increased with the availability of horizontal, vertical and angled
CONNEX connections to gas insulated switchgear and transformers. This
often leads to space saving setups in the substation and reduced
installation time.
n Cable shield tests can be made without unplugging the system, further
reducing installation time.
n There is no unsealing or opening of the actual cable termination required,
eliminating costly oil and insulating gas work during installation.
n Improved safety is assured, using factory pre-assembled and tested
components.

A Socket
1 contact element
2 epoxy socket A B C D

B Contact system
3 contact ring
4 tension cone
5 thrust piece

C Insulating part

D Bell flange
6 gasket
7 threaded counter ring
1 2 3 4 5 6 7

Sample drawing: Cable connecting system HV-CONNEX Size 5-S

(cable with wire screen, application switch gear)

Test standard: TNT 10.97 CONNEX cable connection system

Size
4 5-S 6 6-S

Current rating IN (A) 2500 2500 2500 2500

Max. working voltage Um (kV) 72.5 145 170 245
AC voltage test 50 Hz/1 min (kV) 140 275 325 460
Nominal withstand lightning impulse voltage 1.2/50 s (kV) 325 650 750 1050
Partial discharge 2 x UO (pC) 2 2 2 2
DC voltage test 15 min 6 x UO (kV) 144 304 348 508
Nominal short-time current 0.5 sec (kA) 63 63 63 63
Nominal short-time current 1 sec (kA) 50 50 50 50
Nominal surge current (kA) 160 160 160 160
Gas Insulated Switchgear (GIS)
HV-CONNEX bushings require less space than conventional
type connectors. An extension adapter for conventional cable
connector modules is required when HV-CONNEX is used with
traditional gas insulated switchgear.

Transformers
The HV-CONNEX system offers the possibility of completely
enclosing and testing the transformer at the manufacturing
site, shipping it on-site and connecting it by a simple plug-in
process. This not only permits a more compact transformer
design, but makes handling easier and allows the unit to be
completely tested, signed off and accepted before shipment.

Plug-in Joint Boxes

The HV-CONNEX cable connection system allows plug-in
joint boxes for various geometric configurations to be as-
sembled with fewer components. The complete joint box is
a single unit, and has been fully tested at the factory. There
are huge savings when cables need to be moved many
times during the installation or conversion phase.

CONNEX 170 kV Plug-in Bushing

The HV plug-in bushing can be used wherever overhead lines
need to be connected to high voltage equipment. Using an
HV-CONNEX connection, the equipment can be operated
immediately after connection, without having to open and test
it again at the installation site. Plug-in HV versions can be in-
stalled at any angle, and the bushing swapped out for a cable
connector at any time.

The conventional Alternative:

IXOSIL ESG and IXOSIL ESU
These terminations are used for terminating XLPE insulated
high voltage cables in oil (ESU type) or gas insulated equip-
ment (ESG type). Both types are available in vertical, hori-
zontal and overhead configurations, from 72.5 kV to 245 kV.
Cable Systems | High-Voltage

IXOSIL ESS Outdoor Cable

Termination with Composite
Type ESS terminations are available for voltages from 72.5 kV
to 300 kV, with various creepage distances. A resin-glass fiber
tube with filling compound equipped with silicone sheds gives
the ESS termination extremely high mechanical strength. An
easy to fit head fitting completes the ESS to provide a mainte-
nance-free system.

Highest voltage Um (kV) 72.5 123 145 170 245 300

Standards IEC60840 IEC60840 IEC60840 IEC60840 IEC62067 IEC62067

IEC60815 IEC60815 IEC60815 IEC60815 IEC60815 IEC60815
Rated voltage U (kV) 60 69 110 115 132 138 150 161 220 230 275 287
Lightning impulse withstand voltage (BIL) (kV) 325 550 650 750 1050 1050

IXOSIL ESP Outdoor Cable

Termination with Porcelain
The ESP termination is similar to the composite version,
suitable for the same voltage levels, and utilizes the same
stress cone.

Highest voltage Um (kV) 72.5 123 145 170 245 300

Standards IEC60840 IEC60840 IEC60840 IEC60840 IEC62067 IEC62067

IEC60815 IEC60815 IEC60815 IEC60815 IEC60815 IEC60815
Rated voltage U (kV) 60 69 110 115 132 138 150 161 220 230 275 287
Lightning impulse withstand voltage (BIL) (kV) 325 550 650 750 1050 1050

IXOSIL ESF Flexible

Outdoor Cable Termination
Type ESF flexible terminations are dry, slip-on terminations
for modular assembly. Using silicone sheds, it is ideally suit-
ed for applications in outdoor installations. Type ESF termi-
nations are available for voltages from 52 kV to 170 kV.

Highest voltage Um (kV) 52 72.5 123 145 170

Standards IEC60840 IEC60840 IEC60840 IEC60840 IEC60840

IEC60815 IEC60815 IEC60815 IEC60815 IEC60815
Rated voltage U (kV) 45 47 60 69 110 115 132 138 150 161
Lightning impulse withstand voltage (BIL) (kV) 250 325 550 650 750
IXOSIL EST Outdoor Cable
Termination (Dry Type)
Type EST is ideally suited for both indoor and outdoor appli-
cations. It is available for voltages from 72.5 kV up to 170 kV.
It consists of a flexible ESF type termination and a supporting
insulator. The dry type construction of the terminator enables
it to be installed on the cable in a short period of time. This
can be done in either a horizontal or vertical position prior to
lifting. The terminator and cable can be lift up together using
a crane and installed directly on the pylon. This mounting
procedure permits a quick and economic installation without
having to use a special platform.

Highest voltage Um (kV) 72.5 123 145 170

Standards IEC60815 IEC60815 IEC60815 IEC60815

IEC60840 IEC60840 IEC60840 IEC60840
Rated voltage U (kV) 60 69 110 115 132 138 150 161
Lightning impulse withstand voltage (BIL) (kV) 325 550 650 750
Cable Systems | High-Voltage

IXOSIL Slip-on Joints

IXOSIL slip-on joints consist almost entirely of pre-molded
slip-on silicone parts. This enables the secure and efficient
connection of two polymeric-insulated cables (XLPE, EPR).
The proven slip-on technique ensures minimum installation
time and a maximum operational reliability. The tested and
applied materials comply with all electrical, mechanical and
thermal requirements for rebuilding the cable insulation.
IXOSIL slip-on joints are available in both one piece and
three piece set up and may be used for connecting either
copper or aluminum conductors. Both slip-on joints are avai-
lable with many variants.

IXOSIL One-Piece Slip-on Joints

The one-piece slip-on joints are available for voltages from
72.5 kV to 300 kV. Due to the one-piece construction the
joints are extremely compact in size. The space required in a
joint bay therefore is reduced to a minimum. Each size of the
silicone body covers a range of different insulation diameters.
Up to 5 different outlets are available for efficiently sealing of
fibre optic cable and/or PD sensor cables.

IXOSIL three-part Slip-on Joint

The three-part slip-on joint is available for voltages from 72.5 kV
to 170 kV. The well-tried three-part construction of this joint enab-
les cables of different types and dimensions to be connected.
For example a 630 mm2 EPR cable can be connected to a 500
mm2 XLPE cable. This slip-on joint is also available with an
outlet for a fibre optic cable.

Screen treatment Protective housing

XL, XK, DE S or R MS or MR

XL, XK: Screen version with bonding cable S: Heat-shrinkable sleeve MS: Copper tube with heat-shrinkable sleeve and fill-
DE: Screen version with earthing tap on one R: Fibre-glass reinforced heat-shrinkable ing compound | MR: Copper tube with fibre-glass rein-
side sleeve forced heat-shrinkable sleeve and filling compound

DO G MG

Screen transition Plastic housing and filling compound Copper tube with plastic housing and filling
compound

Maximum Standards Rated Lightning impulse Partial Conductor Diameter over cable
voltage voltage withstand discharge cross section insulation (prepared)
voltage measurement
Um (kV) U (kV) (BIL), (kV) (pC) (mm2) (AWG) (mm) (inch)

72,5 IEC60840 60 69 325 <5 150-1200 300 MCM 4000 MCM 37 87 1.46 3.43
123 IEC60840 110 115 550 <5 240-2500 500 MCM 5000 MCM 45 122 1.77 4.8
145 IEC60840 132 138 650 <5 240-2500 500 MCM 5000 MCM 45 122 1.77 4.8
170 IEC60840 150 161 750 <5 240-2500 500 MCM 5000 MCM 45 122 1.77 4.8
245 IEC62067 220 230 1050 <5 240-2500 500 MCM 5000 MCM 69 122 2.719 4.8
300 IEC62067 275 287 1050 <5 240-2500 500 MCM 5000 MCM 69 122 2.719 4.8
 Installation and Accessories

IXOLINE Ready-Made Cable Systems

A PFISTERER specialty: IXOLINE ready-made cables with
dry IXOSIL or CONNEX connectors. IXOLINE components
make it very easy to assemble short cable connections. The
applications are endless:

n for turn key substations

n for emergency cable connections
n for cables under roads and rail lines
n for short connections between GIS and/or transformers
n for connecting overhead switchgear
n for high-voltage test cables

Installation Made Easy

The installation of high voltage components requires know-
how and care. Our team of technicians carries out the instal-
lation of cable equipment, cable runs, substation cabling, and
testing throughout the world for medium and high voltage.
We offer practical training courses and on-site supervision
to provide needed know-how.

Tools
We have available all the tools and components needed
for the installation and testing of high voltage connections.
We can also provide accessories for improving grounding
characteristics.

High-Voltage Lab
High voltage lab is completely equipped for both inside and
outside testing. All tests are carried out in accordance with
the relevant standards for the application. Testing for fittings
and cable systems are also provided. A considerable amount
of time is spent in doing R&D work to continually upgrade
products to meet the latest market requirements.
The facilities consist of:

n AC test equipment up to 1,000 kV

n Impulse voltage generator up to 1,600 kV
n Induced current system for heat cycle testing
n Artificial rain equipment
n Fully shielded partial discharge measurement room
PFISTERER worldwide
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2011 PFISTERER Kontaktsysteme GmbH | www.pfisterer.com
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